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Structural calculations GRIP ENGINEERS PVT.

LTD Job no-787

STRUCTURAL CALCULATIONS
for 25/5 Tonne D.G.E.O.T.Crane for
for INDURE Pvt. Ltd., New Delhi.
Job No. :- 787
I. BRIDGE GIRDER :-

1 CRANE SPECIFICATIONS :-
CAPACITY OF CRANE =
MAIN HOIST = 25.00 Tonnes
AUX. HOIST = 5.00 Tonnes
SPAN OF CRANE (L) = 15.08 Metres
CLASS/DUTY OF CRANE = 2

2 DATA REQUIRED FOR CALCULATIONS :-


VERTICAL IMPACT FACTOR = 1.30 (Table 2 of IS:807)
VERTICAL SEISMIC FACTOR = - gm
FACTOR FOR VERTICAL FORCES CONSIDERED = 1.300
DUTY FACTOR = 0.95 (Table 2 of IS:807)
FACTOR FOR HORIZONTAL FORCES = 0.05 (Table 2 of IS:807)
SEISMIC FACTOR FOR HORIZONTAL FORCES = - gm
FACTOR FOR HORIZONTAL FORCES CONSIDERED = 0.050
WEIGHT OF TROLLEY = 6.75 Tonnes
CT LEADING WHEEL LOAD (without Impact) = 8.900 Tonnes
CT LEADING WHEEL LOAD (with Impact) = 11.065 Tonnes
CT TRAILING WHEEL LOAD (without Impact) = 6.975 Tonnes
CT TRAILING WHEEL LOAD (with Impact) = 8.560 Tonnes
CT WHEEL BASE = 2.60 Metres
ALLOWABLE VERTICAL DEFLECTION = 1.676 cms
(Clause 7.4.1 of IS:807)
3 SELECTION OF SECTION AS BELOW:-
TOP PLATE :- AREA Ixx Iyy
WIDTH = 430 mm 51.6 6.19 7,950.70
THICKNESS = 12 mm
WEB PLATES :-
HEIGHT = 1,100 mm 66 66,550.00 1.98
THICKNESS = 6 mm
BOTTOM PLATE :-
WIDTH = 374 mm 44.88 5.39 5,231.36
THICKNESS = 12 mm
CENTRE to CENTRE of WEB PLATES = 380 mm
DISTANCE OF B.PLATE FROM WEB BOTTOM = 10 mm

4 PROPORTIONS OF SECTION :-
SPAN/DEPTH RATIO (Should be < 25) = 13.71 O.K.
SPAN/WIDTH RATIO (Should be < 60) = 40.32 O.K.
WIDTH/FLANGE THK RATIO (Should be < 60) = 31.17 O.K.
Io(min) = 144.61 cm^4
FLANGE PROPORTIONS :- Io(max) = 142.18 cm^4
CLEAR FL.WIDTH TO FL.THK RATIO = 31.17 Io(act) = - cm^4 NOT REQD

M/s The Indure Sheet 1 of 9 25/5 T DGEOT


Structural calculations GRIP ENGINEERS PVT. LTD Job no-787

(If this ratio is >38 then one longitudinal stiffner is to be


provided at the centre of the compression flange) a= 81.00 cm
SIZE OF THE LONGITUDINAL STIFFNER b= 37.40 cm
HEIGHT = - mm As = - cm^2
THICKNESS = - mm St.thk = 1.20 cm
AREA = - cm^2 ht = 12.5 cm
thk = 1.6 cm
WEB PROPORTIONS :-

a) FOR UNSTIFFENED WEBS: THE GREATER OF


d1*ª / 816 = 21.31 mm
VERTICAL STIFFNERS
d1*ªfy / 1344 = 12.94 mm 21.31
ARE TO BE PROVIDED
d1 / 85 = 12.94 mm

AS PER ISS DISTANCE BETWEEN FULL DEPTH STIFFNERS = 1,620 mm


AS PER RAIL DISTANCE BETWEEN FULL DEPTH STIFFNERS = 1,980 mm
CONSDERED DISTANCE BETWEEN FULL DEPTH STIFFNERS = c = 1,620 mm

b) FOR VERTICALLY STIFFENED WEBS: THE GREATER OF


h / 180 = 6.11 mm 1 HORIZONTAL
d2*ªfy / 3200 = 5.44 mm 6.11 STIFFNER IS TO BE
d2 / 200 = 5.50 mm PROVIDED
c) FOR VERTICALLY & HORIZONTALLY STIFFENED WEBS: THE GREATER OF
h1 / 180 = 1.21 mm
h2 / 180 = 4.87 mm NO 2nd HORIZONTAL
4.87
d2*ªfy / 4000 = 4.35 mm STIFFNER REQUIRED
d2 / 250 = 4.40 mm
d) FOR VERTICALLY & HORIZONTALLY STIFFENED WEBS: THE GREATER OF
h11 / 180 = 1.21 mm
h12 / 180 = 1.79 mm
h2 / 180 = 3.03 mm 3.03 O.K.
d2*ªfy / 6400 = 2.72 mm
d2 / 400 = 2.75 mm

st
DISTANCE OF 1 CENTRE LINE OF LONG. STIFFNER = 220 mm
DISTANCE OF 2nd CENTRE LINE OF LONG. STIFFNER = - mm

VERTICAL STIFFNERS :-
MINIMUM REQUIRED THICKNESS OF WEB PLATE = t = 3.03 mm
THE MAXIMUM PERMITTED CLEAR DISTANCE BETWEEN VERTICAL
STIFFNERS FOR WEB THICKNESS t = c = 1,620 mm
CLEAR DISTANCE BETWEEN HOR. STIFFNER / COMP. FLANGE
AS APPLICABLE & TENSION FLANGE = d = 877 mm
4
MINIMUM I OF THE VERTICAL STIFFNER = 10,760 mm

SIZE OF THE VERTICAL STIFFNER


HEIGHT = 25.00 mm

M/s The Indure Sheet 2 of 9 25/5 T DGEOT


Structural calculations GRIP ENGINEERS PVT. LTD Job no-787

THICKNESS = 6.00 mm
4
ACTUAL I = 31,250 mm

HORIZONTAL STIFFNERS :-
1. 1st HORIZONTAL STIFFNER
st 4
MINIMUM I OF THE 1 HORZ. STIFFNER = 180,857 mm

SIZE OF THE 1st HORZ. STIFFNER


HEIGHT = 50.00 mm
THICKNESS = 6.00 mm
4
ACTUAL I = 250,000 mm

2. 2nd HORIZONTAL STIFFNER


nd
MINIMUM I OF THE 2 HORZ. STIFFNER = NA mm4

SIZE OF THE 2nd HORZ. STIFFNER


HEIGHT = 45.00 mm
THICKNESS = 8.00 mm
4
ACTUAL I = 243,000 mm

5 PROPERTIES OF ABOVE SECTION :-


2
AREA OF SECTION A = 228.48 cm
DISTANCE EXTREME FIBRE exx = 57.07 cm
4
MOMENT OF INERTIA Ixx = 425,666.31 cm
3
SECTION MODULUS Zxx (t)= 7,459.01 cm
3
SECTION MODULUS Zxx (c)= 7,863.41 cm
4
MOMENT OF INERTIA (whole section) Iyy = 60,838.02 cm
4
MOMENT OF INERTIA (top flange) Iyy = 30,419.01 cm
3
SECTION MODULUS (whole section) Zyy = 2,829.68 cm
3
SECTION MODULUS (top flange) Zyy = 1,414.84 cm
RADIUS OF GYRATION Ryy = 16.32 cms
CENTRE OF GRAVITY C1 = 54.13 cms
DISTANCE EXTREME FIBRE C2 = 57.07 cms
MEAN COMPRESSION FLANGE THK. = 1.20 cms
DEPTH OF GIRDER = 111.20 cms
UNSTIFFENED DEPTH OF WEB = d = 87.70 cms

6 CHECK FOR SELENDERNESS RATIO :-


SELENDERNESS RATIO (L/Ryy) = 92.41
( As per Clause 7.3.2 of IS:807 L/Ryy <300 )
Hence O.K.

7 CHECK FOR DEFLECTION :-


VERTICAL DEFLECTION :-
CT LEADING WHEEL LOAD (without Impact) P1 = 8,900 kg
CT TRAILING WHEEL LOAD (without Impact) P2 = 6,975 kg
CT WHEEL BASE b = 260 cm

M/s The Indure Sheet 3 of 9 25/5 T DGEOT


Structural calculations GRIP ENGINEERS PVT. LTD Job no-787

CRANE SPAN l = 1,508 cm


RESULTANT DIST. FROM L. WHEEL = 114.24 cm
DIST L.WHEEL FROM CENTRE = 57.12 cm
DIST L.WHEEL FROM END a = 696.88 cm
END REACTIONS, Rb = 8,538.79 kg
END REACTIONS, Ra = 7,336.21 kg
INTEGERATION CONSTANT C1 = -2,126,544,398.93
CONSTANT u = -1,563.79
CONSTANT v = 12,404,497.64
CONSTANT w = -8,575,323,675.57
DISTANCE OF POINT OF MAX. DEFLECTION = 765.11 cms

ACTUAL DEFLECTION AT RATED LOAD = 1.21 cms


( with Trolley at the centre of Span )
ALL. DEFLECTION AT RATED LOAD = 1.68 cms
As 1.21 < 1.68 Hence SAFE in Deflection

8 CHECK FOR STRESSES :-

8.1 ALLOWABLE COMPRESSIVE STRESSES IN BENDING :- (for Selected Section)


( As per Clause 6.2.4 of IS:800 )
Y= 310.29 Mpa
X= 317.91 Mpa
K1 (As per Table 6.3 of IS:800) = 1.00
w= 0.50
K2 (As per Table 6.4 of IS:800) = -
ELASTIC CRITICAL STRESS fcb = 335.15 Mpa
( As per Clause 6.2.3 of IS:800 )
T/t= 2.00
d1 / t = 146.17
1344 / ª fy = 85.00
MAXIMUM COMPRESSIVE STRESS = 114.72 Mpa
ALLOWABLE COMPRESSIVE STRESS = 108.98 Mpa
MAXIMUM TENSILE STRESS = 165.00 Mpa
ALLOWABLE TENSILE STRESS = 156.75 Mpa

8.2 VERTICAL STRESSES :-


LEADING WHEEL LOAD (with Impact) = 11,065.00 kg
TRAILING WHEEL LOAD (with Impact) = 8,560.00 kg
RESULTANT DIST. FROM L. WHEEL = 130.85 cm
DIST L.WHEEL FROM CENTRE = 65.43 cm
DIST L.WHEEL FROM END = 688.57 cm
WEIGHT PER METRE OF SECTION = 200.84 kg/m
WEIGHT PER METRE OF CT RAIL = 30.00 kg/m
WEIGHT PER METRE OF PLATFORM = 100.00 kg/m
WEIGHT OF EACH LT MACHINERY = 500.00 Kg
DISTANCE LT M/C FROM RAIL CENTRE = 150.00 cms
END REACTIONS, Rb = 13,658.50 kg
END REACTIONS, Ra = 11,955.58 kg

M/s The Indure Sheet 4 of 9 25/5 T DGEOT


Structural calculations GRIP ENGINEERS PVT. LTD Job no-787

MAXIMUM BENDING MOMENT = 7,372,980.50 kg-cm


VERTICAL BENDING STRESS (t) = 97.00 Mpa
VERTICAL BENDING STRESS (c) = 92.01 Mpa

8.3 HORIZONTAL STRESSES :-


HORIZONTAL FORCES DUE TO :-
a) TROLLEY & LOAD (at each wheel) =
LEADING WHEEL LOAD = 553.25 kg
TRAILING WHEEL LOAD = 428.00 kg
RESULTANT DIST. FROM L. WHEEL = 130.85 cm
DIST L.WHEEL FROM CENTRE = 65.43 cm
DIST L.WHEEL FROM END = 688.57 cm
b) BRIDGE GIRDER = 0.17 kg/cm
WIND LOADS DUE TO :-
a) TROLLEY (at each wheel) = - kg
b) LOAD (at each wheel) = - kg
c) BRIDGE GIRDER = - kg/cm
END REACTIONS, Rb = 657.92 kg
END REACTIONS, Ra = 572.78 kg
MAXIMUM BENDING MOMENT = 355,184.69 kg-cm
HORIZONTAL BENDING STRESS = 12.32 Mpa

8.4 MAXIMUM TOTAL BENDING STRESS = 104.33 Mpa

As 97.00 < 156.75 SAFE in Bend. Stresses in Tension


As 104.33 < 108.98 SAFE in Bend. Stresses in Comp.

9 CHECK FOR SHEAR STRESS IN WEB :-


( As per Clause 6.4.2 a) & Table 6.6A of IS:800 )
DEPTH/THICKNESS RATIO = 146.17
DISTANCE BETWEEN STIFFNERS = c = 162.00 cms
RATIO c/d = 1.47
MAXIMUM AVERAGE SHEAR STRESS = 93.00 Mpa
(As per Clause 6.4.1 of IS:800)
MAXIMUM SHEAR STRESS (0.45*fy) = 112.50 Mpa
MINIMUM OF THE ABOVE TWO = 93.00 Mpa
ALLOWABLE AVERAGE SHEAR STRESS = 88.35 Mpa
MAXIMUM SHEAR NEAR ENDS = 17,106.28 kg

GIRDER END SECTION AS SHOWN:-


TOP PLATE :-
WIDTH = 430 mm
THICKNESS = 12 mm
BOTTOM PLATE :-
WIDTH = 600 mm
THICKNESS = 16 mm
WEB PLATES :-
HEIGHT = 200 mm
THICKNESS = 6 mm
CENTRE to CENTRE of WEB PLATES = 380 mm

M/s The Indure Sheet 5 of 9 25/5 T DGEOT


Structural calculations GRIP ENGINEERS PVT. LTD Job no-787

PROPERTIES OF ABOVE SECTION :-


AREA OF SECTION A = 171.60 cm^2
MOMENT OF INERTIA Ixx = 16,423.62 cm^4
CENTRE OF GRAVITY C1 = 14.05 cms
DISTANCE EXTREME FIBRE C2 = 8.75 cms

SHEAR STRESS IN WEB UP FROM CENTROID = 59.14 Mpa


SHEAR STRESS IN WEB DOWN FROM CENTROID = 64.97 Mpa

MAXIMUM SHEAR STRESS = 64.97 Mpa


As 64.97 < 88.35 Hence SAFE in Shear Stresses

10 CHECK FOR DISTANCE BETWEEN FULL DEPTH STIFFNERS :-


(Please refer Clause 6.7.4.2 of IS:800)
MINIMUM DISTANCE = (0.33*d) = 36.30 cms
MAXIMUM DISTANCE = (1.5*d) = 165.00 cms
DISTANCE CONSIDERED = c = 162.00 cms
As 162.00 ê 165.00
And 162.00 > 36.30 Hence O.K.

11 CHECK FOR MINIMUM THICKNESS OF VERTICAL STIFFNER PLATES :-


ALL STIFFNERS SHALL BEAR AGAINST TOP PLATE AND SHALL BE
WELDED TO THE WEB PLATES. ITS THICKNESS SHALL BE SUFFICIENT
TO RESIST THE TROLLEY WHEEL LOAD IN BEARING ON THE ASSUMP-
TION THAT THE WHEEL LOAD IS DISTRIBUTED OVER A DISTANCE EQUAL
TO THE WIDTH OF THE RAIL BASE PLUS TWICE THE DISTANCE FROM
THE RAIL BASE TO THE TOP OF STIFFNER PLATE.

( As per Clause 6.3 of IS:800 )


PERMISSIBLE BEARING STRESS = (0.75*fy) = 187.50 Mpa
ALLOWABLE BEARING STRESS = 178.13 Mpa
TROLLEY WHEEL LOAD (without Impact) = 8.90 Tonnes
WIDTH OF THE RAIL BASE + TWICE THE
DISTANCE FROM TOP OF STIFFNER = 13.35 cms
MINIMUM STIFFNER PLATE THICKNESS = 3.67 mm
STIFFNER PLATE THICKNESS SELECTED = 5.00 mm
As 5.00 > 3.67 Hence O.K. & SAFE

13 CHECK FOR MINIMUM DISTANCE BETWEEN STIFFNERS :-


TROLLEY WHEEL LOAD (without Impact) = 8.90 Tonnes
SECTION MODULOUS OF CT RAIL = 116.00 cm^3
MINIMUM DISTANCE BETWEEN ADJECENT
STIFFNERS (LONG OR SHORT) = 989.91 mm
CONSIDERED MINIMUM DISTANCE = 810.00 mm
As 810.00 < 989.91 Hence O.K. & SAFE

II. END CARRIAGES :-

1 END CARRIAGE SPECIFICATIONS :-


C.T. WHEEL GUAGE = 3.20 Metres

M/s The Indure Sheet 6 of 9 25/5 T DGEOT


Structural calculations GRIP ENGINEERS PVT. LTD Job no-787

END CARRIAGE WHEEL BASE = 4.80 Metres


L.T. WHEEL BASE = 4.80 Metres

2 DATA REQUIRED FOR CALCULATIONS :-


(When Trolley is at one End)
LIVE LOAD (without Impact) = 14.82 Tonnes
LIVE LOAD (with Impact) = 18.32 Tonnes
DEAD LOAD = 2.99 Tonnes
ALLOWABLE VERTICAL DEFLECTION = 0.53 cms

3 SELECTION OF SECTION AS BELOW:-


TOP & BOTTOM PLATE :-
WIDTH = 228 mm
THICKNESS = 8 mm
WEB PLATES :-
HEIGHT = 520 mm
THICKNESS = 8 mm
CENTRE to CENTRE of WEB PLATES = 220 mm

4 PROPORTIONS OF SECTION :-
SPAN/DEPTH RATIO (Should be < 25) = 9.23 O.K.
SPAN/WIDTH RATIO (Should be < 60) = 22.64 O.K.
WIDTH/FLANGE THK RATIO (Should be < 60) = 26.50 O.K.

5 PROPERTIES OF ABOVE SECTION :-


AREA OF SECTION A = 119.68 cm^2
MOMENT OF INERTIA Ixx = 44,174.78 cm^4
SECTION MODULUS Zxx = 1,648.31 cm^3
MOMENT OF INERTIA (whole section) Iyy = 11,651.95 cm^4
MOMENT OF INERTIA (top flange) Iyy = 5,825.98 cm^4
SECTION MODULUS Zyy = 1022.10 cm^3
RADIUS OF GYRATION Ryy = 9.87 cms
CENTRE OF GRAVITY C1 = 26.80 cms
DISTANCE EXTREME FIBRE C2 = 26.8 cms
MEAN COMPRESSION FLANGE THK. = 0.80 cms
DEPTH OF GIRDER = 53.60 cms
AREA OF WEB (Near End) = 26.88 cm^2

6 CHECK FOR SELENDERNESS RATIO :-


SELENDERNESS RATIO (L/Ryy) = 48.65
( As per Clause 7.3.2 of IS:807 L/Ryy <300 )
Hence O.K.

7 CHECK FOR DEFLECTION :-


ACTUAL DEFLECTION AT RATED LOAD = 0.3681322 cms
( with Trolley at the end of Span )
ALL. DEFLECTION AT RATED LOAD = 0.53 cms
As 0.37 < 0.53 Hence SAFE in Deflection

8 CHECK FOR STRESSES :-

M/s The Indure Sheet 7 of 9 25/5 T DGEOT


Structural calculations GRIP ENGINEERS PVT. LTD Job no-787

8.1 ALLOWABLE COMPRESSIVE STRESSES IN BENDING :- (for Selected Section)


( As per Clause 6.2.4 of IS:800 )
Y= 1,119.80 Mpa
X= 1,134.46 Mpa
K1 (As per Table 6.3 of IS:800) = 1.00
w= 0.50
K2 (As per Table 6.4 of IS:800) = 0.00
ELASTIC CRITICAL STRESS fcb = 1,134.46 Mpa

( As per Clause 6.2.3 of IS:800 )


MAXIMUM COMPRESSIVE STRESS = 152.14 Mpa
ALLOWABLE COMPRESSIVE STRESS = 144.53 Mpa

8.2 VERTICAL STRESSES :-


WEIGHT PER METRE OF SECTION = 107.79 kg/m
END REACTIONS, Ra = Rb = 21,576.86 kg
MAXIMUM BENDING MOMENT = 2,215,623.26 kg-cm
VERTICAL BENDING STRESS = 131.91 Mpa

8.3 HORIZONTAL STRESSES :-


HORIZONTAL FORCES DUE TO :-
a) TROLLEY & LOAD = 1587.50 kg
END REACTIONS, Ra = Rb = 396.88 kg
MAXIMUM BENDING MOMENT = 31,750.00 kg-cm
HORIZONTAL BENDING STRESS = 3.05 Mpa

8.4 MAXIMUM TOTAL BENDING STRESS = 134.96 Mpa


As 134.96 < 144.53 Hence SAFE in Bending Stresses

9 CHECK FOR SHEAR STRESS IN WEB :-


( As per Clause 6.4.2 a) & Table 6.6A of IS:800 )
DEPTH/THICKNESS RATIO = 65.00
DISTANCE BETWEEN STIFFNERS (1.0*d) = 52.00 cms
MAXIMUM AVERAGE SHEAR STRESS = 100.00 Mpa
(As per Clause 6.4.1 of IS:800)
MAXIMUM SHEAR STRESS (0.45*fy) = 112.50 Mpa
MINIMUM OF THE ABOVE TWO = 100.00 Mpa
ALLOWABLE AVERAGE SHEAR STRESS = 95.00
MAXIMUM SHEAR NEAR ENDS = 21,576.86 kg

END CARRIAGE END SECTION AS SHOWN:-


TOP PLATE :-
WIDTH = 228 mm
THICKNESS = 8 mm
BOTTOM FLATS :-
WIDTH = 80 mm
THICKNESS = 20 mm
WEB PLATES :-

M/s The Indure Sheet 8 of 9 25/5 T DGEOT


Structural calculations GRIP ENGINEERS PVT. LTD Job no-787

HEIGHT = 153 mm
THICKNESS = 8 mm
CENTRE to CENTRE of WEB PLATES = 220 mm

PROPERTIES OF ABOVE SECTION :-


2
AREA OF SECTION A = 74.72 cm
4
MOMENT OF INERTIA Ixx = 3,839.43 cm
CENTRE OF GRAVITY C1 = 10.19 cm
DISTANCE EXTREME FIBRE C2 = 7.91 cm

SHEAR STRESS IN WEB UP FROM CENTROID = 61.55 Mpa


SHEAR STRESS IN WEB DOWN FROM CENTROID = 76.22 Mpa

MAXIMUM SHEAR STRESS = 76.22 Mpa


As 76.22 < 95.00 Hence SAFE in Shear Stresses

10 CHECK FOR DISTANCE BETWEEN FULL DEPTH STIFFNERS :-


(Please refer Clause 6.7.4.2 of IS:800)
MINIMUM DISTANCE = (0.33*d) = 17.16 cms
MAXIMUM DISTANCE = (1.5*d) = 78.00 cms
DISTANCE CONSIDERED = (1.0*d) = 52.00 cms
As 52.00 < 78.00
And 52.00 > 17.16 Hence O.K.

11 CHECK FOR MINIMUM THICKNESS OF WEB PLATES :-


( As per Clause 6.7.3.1 b) & Table 6.7 of IS:800 )
I) 1/180 OF SMALLEST CLEAR PANEL = 2.89 mm
II) MAXIMUM OF :-
d2*(fy)^.5/3200 = 0.19 mm
d2/200 = 2.60 mm
GREATER OF I) & II) = 2.89 mm
CONSIDERED THICKNESS OF WEB PLATE = 8.00 mm
As 8.00 > 2.89 Hence O.K.

M/s The Indure Sheet 9 of 9 25/5 T DGEOT